System and method of converting animal wastes to energy and useful by-products

ABSTRACT

A system and method for converting animal waste, in the form of waste slurry, to energy and useful byproducts. A screen mesh filters out large objects from waste slurry and the filtered slurry is chopped and fragmented to reduce binding of fibrous materials. The fragmented slurry is mixed at a rate to maintain solids in the fragmented slurry in suspension while minimizing aeration and turbulence within the mixing unit. A solids recovery unit recovers about 95% of the suspended solids. A polymer is introduced into the solids recovery unit for providing agglomeration of solids particles. The recovered solids are gasified to produce at least methane/ethane gas. The produced gas is provided to an energy production unit to generate electrical and/or heat energy. Liquid remaining after the solids recovery is treated to remove undesirable contaminants to an extent in compliance with water quality standards set for animal waste flushing, animal washing and animal drinking water, as the case may be.

REFERENCE TO PRIORITY APPLICATIONS

This application claims the benefit of and the priority date fromProvisional Application Ser. No. 60/560,409 entitled “System forConverting Animal Wastes to Energy and Useful By-Products” filed Apr. 6,2004, the contents of which are incorporated herein in its entirety, byreference.

FIELD OF THE INVENTION

The invention relates generally to processing animal wastes, principallyin the form of waste slurry, to produce useful by-products such astreated water for irrigation, barn flushing, animal drinking water aswell as organic solids for fertilizers and feedstock for gasification toproduce gas for heat and electricity generation or for alternative fueluses.

BACKGROUND OF THE INVENTION

The animal feeding industry, principally swine and dairy, by virtue ofthe associated animal wastes, has been recognized as the mostsignificant contributor to water pollution in the world. In December2002, the United States Environmental Protection Agency (EPA) and Canadapassed new legislation (“The New Rule”) initially requiring over 12,000large producers to obtain special permits that mandate remediation ofthe wastes they generate. Most of these producers presently have noeconomically viable methods to qualify for these permits and in manycases industry expansion has been frozen and producers are forced tooperate below capacity. The animal wastes from large swine and dairyfarms, known as CAFO'S (Concentrated Animal Feeding Operations) in NorthAmerica, range in the billions of pounds and are a combination of urine,feces and wash water. These wastes typically are piped to a “lagoon”, apit used to hold wastes for up to about six months. The more densesolids fall to the bottom of the lagoon where they receive minimaltreatment and have to be excavated and disposed of periodically. Anaccepted practice for many years is to spray the liquid portion of thewastes over adjoining land parcels and fields as a fertilizer. Theliquid is rich in the nutrients of phosphorous, potassium, and nitrogenwhich are aids to crop growth. As a result of such spraying practices,farm fields in over 500 U.S. counties have become overburdened withthese nutrients such that the crops can no longer absorb them. When thisoccurs, the excess nutrients runoff and enter drinking water wells,streams and coastal bays.

SUMMARY

An embodiment of the invention comprises a screen mesh sized to screenout relatively large objects in waste slurry flushed from an animal barnor retention area, a chopper unit configured to receive the screenedwaste slurry and fragment the waste slurry for reducing the binding offibrous materials contained within the screened waste slurry, a mixingtank configured to receive the fragmented waste slurry and for mixingthe fragmented waste slurry so as to maintain solids in suspensionwithin the fragmented waste slurry and a solids recovery unit configuredto remove at least a predetermined amount of suspended solids from thefragmented waste slurry thereby producing a solids output and a liquidoutput. A polymer additive, as for example, one selected from the groupconsisting of polyacrylamide, ferric chloride and ferric sulfate, isintroduced into the solids recovery unit for providing agglomeration ofsolids particles.

Another embodiment of the invention includes a gas production unitconfigured to receive the solids output and produce gas therefrom.Preferably, the gas produced is methane/ethane gas. Yet anotherembodiment includes an energy production unit configured to generateelectrical and/or heat energy from the produced gas. Yet anotherembodiment includes a water treatment unit configured to removeundesirable contaminants from the liquids output. Particularcontaminants are selected from but not limited to the group consistingof nutrients, pathogens, viruses and coliforms. Coliforms consist of arelated group of bacteria species and are found typically in human andanimal wastes and normally are fecal in origin. Escherichia coli 0157:H7, otherwise referred to as, E. coli, is a coliform species found inthe intestinal tract of warm-blooded animals. Its presence can beindicative of fresh pollution from human or animal waste. Althoughnormally benign, some E. coli strains may be deadly. The embodiments ofthe present invention address the necessity of reducing the E. colicontent of processed animal wastes to acceptable levels.

Another embodiment is a process or method of converting animal waste inthe form of waste slurry into energy and useful byproducts comprisingpassing the waste slurry through a mesh screen to filter out relativelylarge objects from the waste slurry, fragmenting the filtered wasteslurry for reducing binding of fibrous materials contained within thefiltered waste slurry, mixing the fragmented waste slurry to maintainsolids in suspension within the fragmented waste slurry and removing atleast a minimum amount of suspended solids from the fragmented wasteslurry to produce a solids output and a liquid output. Yet anotherembodiment includes removing at least 75% of the solids content from thefragmented waste slurry. Yet another embodiment includes heating theremoved solids content to reduce solids moisture content to about 50%.Yet another embodiment includes gasifying the reduced moisture contentsolids to produce at least methane/ethane gas. Yet another embodimentincludes exhausting the produced gas into the atmosphere in compliancewith established air quality standards. Yet another embodiment includesproducing electrical and/or heat energy from the produced gas. Yetanother embodiment includes removing undesirable contaminants from theliquid output to the extent required to comply with predefined waterquality standards for washing down the growing barns and/or saferirrigation water.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a conventional animal waste removal andmanagement system utilizing a barn and a disposal lagoon; and

FIG. 2 is a schematic view of an animal waste removal and managementsystem configured in accordance to an embodiment of the presentinvention.

DETAILED DESCRIPTION

Prior to a discussion of embodiments of the invention it is instructiveto appreciate an example of a conventional animal waste removal systemutilizing a flush system and technique. Referring to FIG. 1, an animalbarn or other confinement structure 110 includes under floor level wasteslurry pits 112. The slurry pits 112 collect various types of animalwaste elements such as urine, feces and perhaps even small fetuses.Water, presumably meeting animal wash and cooling purity standards, ispumped through clean water inlet 114 for animal washing activities andis also mixed with recycled lagoon (118) water and flushed through thewaste slurry pits 112. The flushed waste slurry is piped directly intolagoon 118 through conduit 116. Typically, the waste slurry comprisesabout 0.5 to 3% solids content. Water is drawn from lagoon 118 by meansof water pump 120 and recycled through conduit 128 back to the slurrypits 112 to further flush the slurry. Alternately, diluted waste slurrymay be diverted, through conduit 124 for land application purposes.

From the foregoing, it should be apparent that much more attention needbe devoted to the major re-thinking of animal waste processing anddisposal. Accordingly, reference is made to FIG. 2, illustrating anembodiment 200 of the invention. Structure 110 may be similar to theanimal barn referred to in FIG. 1 wherein confined animals may behoused, fed, milked as in the case of dairy cows, washed and kept undercover. Waste material excreted by the animals, drops into and iscollected in slurry pits 112. Conduit 216 carries the collected wasteslurry to a mechanical screen unit 218 having a mesh size ofapproximately 2 inches to capture relatively large objects such as trashand animal fetuses. It should be understood that the screen mesh sizemay be selected of differing dimensions according to a desiredfiltration capability. It should also be understood that in thoseapplications where the slurry pits contain a screening device or whenthe CAFO's, for example, include a screening operation in their wastemanagement process, then in such case, the necessity of mechanicalscreen unit 218 is obviated. The screened waste slurry proceeds to achopper pump 220 for fragmenting the slurry into smaller aggregates inorder to reduce the binding effect of larger fibrous materials in thescreened waste slurry. The pumping rate of chopper pump 220 is selecteddependent upon waste slurry processing demands. For example, a barnsized to accommodate 4000 swine or 500 milking cows, which represents asmall concentrated animal feeding operation (CAFO) could require a flowrate of about 20 gallons per minute for proper flushing of waste slurryfrom barn 110. The specifications for chopper pump 220 are selected forprocessing the screened waste slurry at a rate at least as fast as theflow rate for the particular CAFO of interest.

The fragmented waste slurry is then fed to a wet well or mixing tank 224through a mixing tank inlet screen 222. The mixing tank includes amixing device designed to maintain the solids in the fragmented wasteslurry in suspension with a minimum of mixing turbulence. As an example,for the above flow rates, a 20 hp motor with a 4 foot diameter impellerprovides the intended function with minimal aeration and physical damageto mixing tank contents as it is filling. The waste slurry is dischargedfrom mixing tank 224 through outlet 228 under the action of dischargepump 230. It is to be understood that in those applications where theCAFO's, for example, include a mixing operation in their wastemanagement process, then in such case, the necessity of mixing tank 224is obviated.

The discharge from mixing tank 224 is fed to solids recovery module(SRM)/unit 232, a centrifuge separation device capable of separatingapart the suspended solids content and the liquid content of thefragmented waste slurry. A polymer additive such as polyacrylamide,ferric chloride or alum (ferric sulfate) is introduced into the solidsrecovery unit to provide very effective agglomeration of solidsparticles. A typical particle size for the suspended solids is about 40microns in diameter and the solids recovery unit 232 breaks apart thesolids particles to within the range of about 5 to 10 microns indiameter. The solids recovery unit 232 removes about 75% to 98% of thesuspended solids from the fragmented waste slurry. Under normaloperation, solids removal is at least a minimum of 95% of the suspendedsolids. Furthermore, the solids recovery unit produces a solids outputhaving about 60% to 80% moisture and under normal operation a maximum ofabout 75% moisture. Advantageously, the removal of 95% of the suspendedsolids by the solids recovery unit 232 also results in the removal ofsufficient nutrients identified by the Environmental Protection Agency's“New Rule” from the liquid content to reduce the typical land arearequirement for irrigation by about 90%. Commercially available units,such as the Wesffalia Centrisys Centrifuge from the CentrisysCorporation of Kenosha, Wis., may be utilized to produce treated anddewatered solids.

At the user's choice, the separated liquid content is carried by conduit250 to either water treatment module (WTM)/unit 262 or under the actionof pump 252, back to the barn 110 as recycled flush liquid for flushingthe slurry pits 112. Further at the user's discretion, treated liquidcan be directly utilized by a storage and irrigation system 260 to beused to irrigate desired land parcels. The water treatment unit 262receives the separated liquid content and processes it to further removeremaining nutrients, pathogens, viruses and coliforms. Commerciallyavailable units, such as the MEMCOR Membrane Biological Reactor, may beutilized to produce water complying with purity standards establishedfor animal drinking water. Alternately, water may be produced just belowanimal drinking quality standards, but sufficiently high to comply withquality standards established for washing down the animals, recyclinganimal wastes and which would require minimal land acreage forirrigation. Advantageously, the water treatment unit 262 is very costeffective compared to conventional water treatment or water “polishing”systems in that the received liquid content is approximately 95% solidsfree and mostly nutrient free as a result of the waste slurry processingin the solids recovery unit 232. Furthermore, due to the purity of thewater produced, the high capital and operating costs of lagoons,irrigation and crop growing, is markedly reduced.

At the user's choice, the solids output from the solids recovery unit232 is conveyed by conveyance device 234 to either a solids storage bin236 or to gas production module (GPM)/unit 238. Depending upon thenature of the solids output, the solids conveyed may be at a rate, forexample, of about 1000 pounds per hour. Obviously, a smaller or greateramount of solids conveyed per hour, depends upon the capacity ofselected system units. The solids conveyed to storage bin 236 have ahigh organic content and the bin may be either a permanent structure ormay be mobile and adapted for movement from one location to another,which facilitates being filled at one location and emptied at anotherlocation. The solids output have a market value as fertilizer forspreading over crop producing fields, either under the control of theuser or to be sold for use by others. In this regard, an embodiment ofthe invention provides a financial return to the user in addition to thebenefit of efficient animal waste removal and management.

At the user's choice, the solids output may be conveyed to gasproduction unit 238 configured for gasification of the received solidsoutput. The gas production unit 238 includes a heated input hopper (notshown) that serves to heat the received solids output to reduce thesolids moisture to approximately 50% during a pre-gasification time ofabout one hour. The solids output is converted primarily tomethane/ethane gas that has a heating value of about 600 to 1200 BTU. Atthe user's choice, and due to the nature of the gas produced, the gasmay be flared into the atmosphere without violating existing air qualitystandards. As a by-product of the gas production, a small amount of ashis produced and collected in receptacle 242. A typical ash productionrate is about 50 to 100 pounds per hour. Obviously, ash production ratesdepend upon processing capacities of the various processing unitscomprising the disclosed system and the amount of ingredients containedin the waste stream. The ash is a valuable by-product as an additivethat can be either added to animal feed or marketed separately. Againand in this regard, an embodiment of the invention provides a furtherfinancial return to the user in addition to the benefit of efficientanimal waste removal and management. The gas production unit 238 isconfigured to minimize ash production and thereby reduce the number ofancillary processes and removal steps for ash management whileincreasing the heating value and volume of the produced gas. Acommercially available gasification unit is the Brookes GasificationProcess unit from BGP, Inc. of Scarborough, Ontario, Canada.

At the user's choice, the un-flared produced gas may be piped throughconduit 240 to the energy production module (EPM)/unit 244. The energyproduction unit 244 is preferably, but not necessarily, a micro-turbineconfigured to produce either or both, electrical energy (shown as block246) and heat energy (shown as block 248). Typical energy production forthe system disclosed herein is about 150 to 200 kilowatt-hourselectrical energy and the energy production unit is about 50 to 65%efficient when combining both electrical and heat energy. The user maychoose to apply the produced energy for its own applications for addedconvenience and to reduce site operating costs, including overall animalwaste removal and management costs. Alternately, the user may choose tomarket the produced energy and realize a financial return as an offsetto system operation costs. A commercially available energy productionunit is the CP 30, available from the Capstone Turbine Corporation ofChatsworth, Calif.

Although embodiments of the invention have been described, it is to berecognized that modifications may be made without departing from thenovel concepts disclosed herein. Accordingly, it is intended that thescope of the invention be determined by the appended claims and theirequivalents.

1. A system for converting animal waste, in the form of waste slurry, touseful by-products comprising: a chopper unit configured to receivewaste slurry from a waste slurry source and fragment the waste slurryfor reducing binding of fibrous materials contained within the wasteslurry; and a solids recovery unit configured to remove at least apredetermined minimum amount of solids from the fragmented waste slurryproducing thereby a solids output and a liquid output.
 2. The system ofclaim 1, wherein the minimum amount of recovered solids is at least 75%of the solid content of the waste slurry.
 3. The system of claim 2,wherein the solids recovery unit is configured to produce a solidsoutput having a moisture content in the range of about 60% to 80%. 4.The system of claim 3, further comprising a solids storage bin sized tostore the solids output for future usage and/or as feedstock forgasification.
 5. The system of claim 3, further comprising a gasproduction unit comprising an input hopper adapted to receive the solidsoutput, the gas production unit configured to produce methane/ethane gasfrom the received solids output.
 6. The system of claim 5, wherein thegas production unit is configured to produce gas having a heating valuein the range of about 600 to 1200 BTU.
 7. The system of claim 5, whereinthe gas production unit is adapted to exhaust the produced gas into theatmosphere in a manner complying with pre-defined environmental airquality standards.
 8. The system of claim 5, wherein the gas productionunit further comprises a heated input hopper adapted to reduce solidsmoisture content to about 50%.
 9. The system of claim 5, furthercomprising an energy production unit adapted to generate electricalenergy from the gas produced from the gas production unit.
 10. Thesystem of claim 9, wherein the electrical energy produced by the energyproduction unit is about 150 to 200 kilowatt-hours.
 11. The system ofclaim 5, further comprising an energy production unit adapted togenerate heat energy from the gas produced from the gas production unit.12. The system of claim 9 wherein the energy production unit is amicro-turbine configured to produce electrical energy.
 13. The system ofclaim 11, wherein the energy production unit is a micro-turbineconfigured to produce heat energy.
 14. The system of claim 3, furthercomprising a water treatment unit adapted to remove undesirablecontaminants from the liquid output.
 15. The system of claim 14, whereinthe removed contaminants are selected from the group consisting ofnutrients, pathogens, viruses and coliforms.
 16. The system of claim 14,wherein the undesirable contaminants are removed to the extent requiredto comply with predefined water quality standards for water used forwashing down animals and/or for flushing animal wastes.
 17. The systemof claim 14, wherein the contaminants are removed to the extent requiredto comply with water quality standards for animal drinking water. 18.The system of claim 1 further comprising a screen mesh interposedbetween the waste slurry source and the chopper unit configured andsized to screen out relatively large objects from the waste slurry; 19.The system of claim 1, further comprising a mixing tank configured toreceive the fragmented waste slurry and for mixing the fragmented wasteslurry so as to maintain solids in suspension within the fragmentedwaste slurry.
 20. The system of claim 1, further comprising means forintroducing a polymer additive selected from the group consisting ofpolyacrylamide, ferric chloride and ferric sulfate into the solidsrecovery unit for providing agglomeration of solids particles.
 21. Asystem for converting animal waste, in the form of waste slurry, toenergy and useful by-products comprising: a screen mesh configured andsized to screen out relatively large objects from the waste slurry; achopper unit configured to receive the screened waste slurry andfragment the screened waste slurry for reducing binding of fibrousmaterials contained within the screened waste slurry; a mixing tankconfigured to receive the fragmented waste slurry and for mixing thefragmented waste slurry so as to maintain solids in suspension withinthe fragmented waste slurry; and a solids recovery unit configured toremove at least a predetermined minimum amount of suspended solids fromthe fragmented waste slurry producing thereby a solids output and aliquid output.
 22. A method for converting animal waste, in the form ofwaste slurry, to useful by-products comprising the steps of: fragmentingthe waste slurry for reducing binding of the fibrous materials containedwithin the waste slurry; and removing at least a predetermined minimumamount of solids from the fragmented waste slurry to produce a solidsoutput and a liquid output.
 23. The method of claim 22, furthercomprising the step of removing at least 75% of the solids content fromthe fragmented waste slurry.
 24. The method of claim 23, furthercomprising the step of storing the removed solids content for futureuse.
 25. The method of claim 23, further comprising the step of heatingthe removed solids content to reduce solids moisture content to about50%.
 26. The method of claim 25 further comprising the step of gasifyingthe reduced moisture content solids to produce known gas.
 27. The methodof claim 26, wherein the gasifying step includes the step of producingmethane/ethane gas.
 28. The method of claim 27 wherein the step ofgasifying includes the step of producing gas having a heating value inthe range of about 600 to 1200 BTU.
 29. The method of claim 26, furtherincludes the step of exhausting the gas into the atmosphere inaccordance with predefined environmental air quality standards.
 30. Themethod of claim 26, further comprising the step of processing the gas toproduce electrical energy.
 31. The method of claim 26, furthercomprising the step of processing the gas to produce heat energy. 32.The method of claim 22, further comprising the step of removingundesirable contaminants from the liquid output to the extent requiredto comply with predefined water quality standards for water used forwashing down animals and/or flushing animal wastes.
 33. The method ofclaim 22, further comprising the step of removing undesirablecontaminants from the liquid output to the extent required to complywith predefined water quality standards for irrigation water.
 34. Themethod of claim 22, comprising, prior to the fragmenting step, the stepof filtering the waste slurry to remove relatively large objects fromthe waste slurry.
 35. The method of claim 22, further comprising mixingthe fragmented waste slurry so as to maintain solids in suspensionwithin the fragmented waste slurry. 36 The method of claim 22 furthercomprising the step of introducing a polymer additive selected from thegroup consisting of polyacrylamide, ferric chloride and ferric sulfateinto the fragmented waste slurry for providing agglomeration of solidsparticles.
 37. A method for converting animal waste, in the form ofwaste slurry, to useful by-products comprising the steps of: filteringthe waste slurry to remove relatively large objects from the wasteslurry; fragmenting the filtered slurry waste for reducing binding ofthe fibrous materials contained within the filtered waste slurry; mixingthe fragmented waste slurry so as to maintain solids in suspensionwithin the fragmented waste slurry; and removing at least apredetermined minimum amount of suspended solids from the fragmentedwaste slurry to produce a solids output and a liquid output.
 38. Themethod of claim 37 further comprising the step of introducing a polymeradditive selected from the group consisting of polyacrylamide, ferricchloride and ferric sulfate into the fragmented waste slurry forproviding agglomeration of solids particles.